Coating for protecting a substrate

Abstract

A mixture curable to provide a fibre reinforced coating material for protecting a substrate. The mixture comprises a phenolic resin or a polyfurfuryl alcohol resin, a hardener, a thixotropic additive, and fibres.

1 . A mixture curable to provide a fibre reinforced coating material for protecting a substrate, wherein the mixture comprises:
 a phenolic resin or a polyfurfuryl alcohol resin;   a hardener;   a thixotropic additive; and   fibres.   
     
     
         2 . A mixture according to  claim 1 , wherein the phenolic resin comprises phenol-formaldehyde resin with a free formaldehyde to phenol molar ratio of less than one. 
     
     
         3 . A mixture according to  claim 1 , wherein the hardener comprises an acidic catalyst. 
     
     
         4 . (canceled) 
     
     
         5 . A mixture according to  claim 1 , wherein the thixotropic additive comprises: fumed silica, nano-clays, cellulosic materials, or mineral powders. 
     
     
         6 . A mixture according to  claim 1 , wherein the thixotropic additive comprises cellulosic materials. 
     
     
         7 . A mixture according to  claim 6 , wherein the cellulosic materials comprise fibrillated cellulose. 
     
     
         8 . (canceled) 
     
     
         9 . A mixture according to  claim 1 , wherein the mixture comprises a silane additive. 
     
     
         10 . A mixture according to  claim 1 , wherein the mixture is a three-part mixture, wherein
 a first part of the three-part mixture comprises the phenolic resin or the polyfurfuryl alcohol resin and the thixotropic additive;   a second part of the three-part mixture comprises the hardener; and   a third part of the three-part mixture comprises the fibres.   
     
     
         11 . A mixture according to  claim 10 , wherein the three-part mixture comprises 30 to 80% by weight of the first part. 
     
     
         12 - 13 . (canceled) 
     
     
         14 . A mixture according to  claim 10 , wherein the three-part mixture comprises 1 to 15% by weight of the second part. 
     
     
         15 - 16 . (canceled) 
     
     
         17 . A mixture according to  claim 10 , wherein the three-part mixture comprises 5 to 50% by weight of the third part. 
     
     
         18 - 19 . (canceled) 
     
     
         20 . A method of protecting a substrate, the method comprising:
 applying a mixture to a substrate, wherein the mixture comprises: a phenolic resin or a polyfurfuryl alcohol resin, a hardener, a thixotropic additive, and fibres; and   allowing the mixture to cure to provide a substrate comprising a fibre reinforced coating material for protecting the substrate.   
     
     
         21 . A method according to  claim 20 , wherein the mixture is a three-part mixture, wherein
 a first part of the three-part mixture comprises: the phenolic resin or the polyfurfuryl alcohol resin and the thixotropic additive;   a second part of the three-part mixture comprises the hardener; and   a third part of the three-part mixture comprises the fibres; and   
       wherein the method comprises mixing the first part, second part, and third part of the three-part mixture and allowing the three-part mixture to cure to provide a substrate comprising a fibre reinforced coating material for protecting the substrate. 
     
     
         22 . A method according to  claim 21 , wherein the method comprises mixing the first part and the second part, and subsequently mixing the mixed first and second parts with the third part. 
     
     
         23 . A method according to  claim 22 , wherein the mixture is applied to the substrate by spraying the mixture on to the substrate, and wherein the method comprises:
 ejecting the mixed first and second parts from a first outlet of an applicator; and   ejecting the third part through a second outlet of the applicator such that the mixed first and second parts mix with the third part following ejection from the applicator.   
     
     
         24 . A method according to  claim 23 , wherein the method comprises:
 mixing the mixed first and second parts with the third part in mid-air following ejection from the respective first and second outlets.   
     
     
         25 . A method according to  claim 24 , wherein the method comprises:
 orientating the respective first and second outlets such that a flow of ejected mixed first and second parts intercepts a flow of ejected third part in mid-air.   
     
     
         26 . A method according to  claim 20 , wherein the method comprises:
 applying the mixture on the underside of a substantially horizontal surface of a substrate or on an inclined or substantially vertical surface of a substrate.   
     
     
         27 . A method according to  claim 26 , wherein the method comprises:
 applying the mixture on the underdeck of an oil or gas rig.   
     
     
         28 . A fibre reinforced coating material for protecting a substrate, the fibre reinforced coating material being the cured product of a mixture comprising: a phenolic resin or a polyfurfuryl alcohol resin, a hardener, a thixotropic additive, and fibres. 
     
     
         29 . (canceled)